Char-Broil Traditional 4638200 Assembly Manual
4638200
ASSEMBLY MANUAL
THIS GRILL IS FOR
OUTDOOR USE ONLY
CAUTION: Read and follow all safety
statements, assembly instructions, and
use and care directions before
attempting to assemble and cook.
INSTALLER/ASSEMBLER: Leave
these instructions with consumer.
TO CONSUMER: Keep this manual for
future reference.
4638200 / 0-4165013 (11-26-01)
WARNING
Failure to follow all manufacturers
instructions could result in serious
personal injury and/or property
damage.
CAUTION
Some parts may contain sharp edges
- especially as noted in the manual!
Wear protective gloves if necessary.
If you have any questions or need
assistance during assembly, please
call 1-800-241-7548.
Visit us on the web at:
www.charbroil.com
4638200 1
FOR YOUR SAFETY
1. Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
2. An LP Tank not connected for use
shall not be stored in the vicinity of
this or any other appliance.
FOR YOUR SAFETY
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. If odor continues, immediately call
your gas supplier or your fire
department.
Call Grill Service Center For Help And Parts
If you need help or warranty parts call (1-800-241-7548 or
send a FAX to 1-706-576-6355.
Business hours: Open 24 hours - Seven days a week
To order non-warranty replacement parts or accessories (grill
cover, cleaners, paint) call 1-800-993-2677or send a FAX to 1706-565-2121.
Important: Fill out Warranty Information below
Installation Safety Precautions
This grill is designed for natural gas use at 7 inch water
column supply pressure. Verify supply pressure with your
local gas company. Not for use with LP gas.
Grill installation must conform with local codes, or in their
absence with National Fuel Gas Code, NFPA 54 / ANSI
Z223.1. Grill is not for use in or on recreational vehicles and/
or boats.
All electrical accessories (such as rotisserie) must be
electrically grounded in accordance with local codes, or
National Electrical Code, ANSI / NFPA 70. Keep any
electrical cords and/or fuel supply hoses away from any hot
surfaces.
This grill is safety certified for use in the United States only.
Do not modify for use in any other location. Modification will
result in a safety hazard.
Safety Symbols
The symbols and boxes shown below explain what each
heading means. Read and follow all of the messages found
throughout the manual.
DANGER: Indicates an imminently hazardous
situation which, if not avoided, will result in death or
serious injury.
Warranty Information
Model Number _________________________________
UPC Label Lot # GG ___ ___ ___ ___ ___ ___
(on carton)
WARNING: Be alert to the possibility of serious
bodily injury if the instructions are not followed. Be
Serial Number _________________________________
sure to read and carefully follow all of the messages.
Date Purchased ________________________________
CAUTION: Indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
For residential use only. Do not use for commercial cooking.
Certified Grill Parts And Accessories®, Char-Broil and Design®, Char-Broil (Gas Grill Briquettes)®, Char-Diamonds®, Cooking Zon e and Design®, Diamond Flame®, Executive Chef®, Faststart®, Flare Fighter®, FlavorMaster®, Gas Grill Silouette
and Design®, H2O Smoker®, Lava Flame®, MasterFlame®, MasterFlame Precision Cooking System®, PowerSpark®, Quantum®, VIP®, PrecisionFlame and Design®, Sierra®, and TruFlame® are registered Trademarks of the W.C. Bradley
Company. Thermos® is a registered trademark of the Thermos Company and its affiliates.
Artisan Collection by Char-Broil , C3 and Design, Char-Broil and Design, Flame Design, FlavorTents, Grill 2 Go, Grillin Stick, Keeper of the Flame, Keepers of the Flame, Natural Grip, Outdoor Cooking Collection and Design,
Patio Bistro, PrecisionFlame, Pro-Check, QuickSet Grills and Design, SmokerTents, The Big Easy, The Minute Grill, The Edge, The Tuscan Collection, and The Urban Grill are Trademarks of the W.C. Bradley Company.
Universal Grill Parts and Design is a trademark of the Thermos Company and its affiliates.
Protected under one or more of the following U.S. Patents: 4,598,692; 4,624,240; 4,747,391; 4,747,391; 4,817,583; 4,924,846; 4,989,579; 5,003,960; 5,076,256; 5,076,257; 5,090,398; 5,109,834; 5,224,676; 5,277,106; 5,421,319; 5,441,226;
5,452,707; 5,458,309; 5,566,606; 5,566,606; 5,579,755; 5,582,094; 5,613,486; 5,649,475; 5,706,797; 5,711,663; 5,765,543; 5,931,149; 5,996,573; 6,095,132; 6,135,104; 6,279,566; D282,619; D339,714; D341,292; D343,337; D358,059; D361,466;
D364,535; D372,637; D373,701; D377,735; D383,035; D397,910; D405,643; D405,643; D406,005; D406,009; D413,043; D413,229; D413,229; D414,982; D415,388; D416,164; D416,441; D416,441; D417,587; D422,516; D423,274; D423,876;
D428,303; D435,396; D436,004; D438,059; D438,060; D438,427; D439,110; D442,505; D443,179; D443,354; D447,384; D447,385; D447,909; D448,610; D448,614; D448,615; D448,616; D448,975; and D449,492. Other Patents Pending.
injury.
2 4638200
Table of Contents
Warnings ..................................................................... 2
Warranty Information ................................................. 2
Installation Safety Precautions................................. 2
Table of Contents....................................................... 3
Before Beginning Assembly ...................................... 3
Warranty ...................................................................... 3
Parts List and Diagram.............................................. 4
Assembly Instructions ............................................ 5-10
Leak Test .................................................................... 9
Use and Care.......................................................... 11-14
Troubleshooting......................................................... 15
Warranty
Manufacturer warrants to the original consumer-purchaser that this
product shall be free from defects in workmanship and materials under
normal and reasonable use and correct assembly (if assembled by
consumer-purchaser), as follows:
(1) The aluminum top and bottom castings for the life of original
purchase, excluding the paint finish;
(2) The burner/venturi assembly on Traditional and QuickSet Grills
for a period of three (3) years from the date of purchase; five (5) years
on Big Easy; and
(3) All other parts for a period of one (1) year from the date of
purchase.
Manufacturer will, at its option, refinish or replace any product or
part found to be defective during the warranty period. Manufacturer will
require you to return the part(s) claimed to be defective, for its
inspection, freight or postage prepaid.
If you wish to obtain performance of any obligation under this
limited warranty, you should write to:
Consumer Warranty / P.O. Box 1240
Columbus, GA 31902-1240
Before Beginning Assembly
s Read all assembly instructions. The pictures are only
for reference; they do not contain all the information
needed to correctly assembly your grill.
s Metal edges can be sharp. Use caution during
assembly and use.
s Necessary tools for assembly of your grill include
screwdrivers (flathead and phillips), pliers and
adjustable wrench. A 3/8" and
7/16" nut driver would be ideal.
Manufacturer may require reasonable proof of purchase and we
suggest you keep your receipt. In the state of California only, if
refinishing or replacement of the product is not commercially practicable,
the retailer selling this product or Manufacturer will refund the purchase
price paid for the product, less the amount directly attributable to use by
the original consumer-purchaser prior to discovery of the nonconformity.
In addition, in the state of California only, you may take the product to
the retail establishment from which it was purchased or to any retail
establishment selling this product in order to obtain performance under
this warranty.
This warranty does not include the cost on any inconvenience or
property damage due to failure of the product and does not cover
damage due to misuse, abuse, accident, damage arising out of
transportation of the product, or damage incurred through commercial
use of the product. This express warranty is the sole warranty given by
the manufacturer and is in lieu of all other warranties, express or implied,
including implied warranty of merchantability or fitness for a particular
purpose. Neither Manufacturer dealers nor the retail establishment
selling this product has any authority to make any warranties or to
promise remedies in addition to or inconsistent with those stated above.
Manufacturer's maximum liability, in any event, shall not exceed the
purchase price of the product paid by the original consumer-purchaser.
Some states do not allow the exclusion or limitation of incidental or
consequential damages. So the above limitations or exclusions may not
apply to you. This warranty gives you specific legal rights and may also
have other rights which vary from state to state.
You may have hardware left over after completing assembly of your grill. This is normal as in some cases we have included extra
hardware to ensure that you have enough. Size and type of hardware used in assembly of your grill may vary but will not affect grill
integrity, performance or assembly.
4638200 3
O
D
Q
F
Key Description Qty. Part No.
A SwingAway Bottom 1 4152125
B Cooking Grate 1 4152741
C Shelf 2 4154259
D Handle 1 4154474
E Gas Supply Tube 1 4156394
F SwingAway Top 1 4156449
G Side Shelf Tube 2 4502212
H Post Tube Support 1 4502219
I Post Assembly 1 4504606
J Briquets 1 4158125
K Briquet Grate 1 4157101
L Vaporiser Bar 1 4156418
M Burner Assemby 1 4505010
N Console 1 4526050
O Grill Lid 1 4580190
P Grill Bottom 1 4581041
Q Logo Plate 1 4157148
-- Hardware Bag 1 4254020
R Ignitor 1 4153713
S Ignitor Wire 1 4153720
T Collector Box 1 4500208
U Knob 2 4154203
V Grease Clip 1 5156607
W Valve Assembly 1 4524056
T
S
L
M
A
B
C
P
G
This label contains the model and serial number for your grill. You
should write this information on page 2 in this manual.
H
E
J
K
V
R
I
Remove end of rating label on post
assembly and apply to your warranty
card in box #5. If label cannot be
removed, write the numbers on your
warranty card.
C
G
N
U
W
4 4638200
ASSEMBLY
1
Tip: Use the Post Assembly base as a template for drilling holes into
deck.
Attaching Grill to Wood Deck
s Wrench tighten all hex nuts. Make sure post
assembly is fully secured and vertical before
proceeding.
Qty. 4
Qty. 4
Qty. 4
Front
Place slot
to right
Wood
Deck
2
Gas Supply Tube
A
Place longest end of Gas
Tube into rectangle hole
and slide downward into
Post.
B
Align Gas Tube so that
end comes out of round
hole on back of Post.
4638200 5
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